U.S. patent number 7,724,532 [Application Number 11/501,184] was granted by the patent office on 2010-05-25 for handheld computing device.
This patent grant is currently assigned to Apple Inc.. Invention is credited to Stephen Brian Lynch, Stephen Paul Zadesky.
United States Patent |
7,724,532 |
Zadesky , et al. |
May 25, 2010 |
**Please see images for:
( Certificate of Correction ) ** |
Handheld computing device
Abstract
A handheld computing device is disclosed. The handheld computing
device includes an enclosure having structural walls formed from a
ceramic material that is radio-transparent.
Inventors: |
Zadesky; Stephen Paul (Portola
Valley, CA), Lynch; Stephen Brian (Alamo, CA) |
Assignee: |
Apple Inc. (Cupertino,
CA)
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Family
ID: |
46324878 |
Appl.
No.: |
11/501,184 |
Filed: |
August 7, 2006 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20060268528 A1 |
Nov 30, 2006 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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10884172 |
Jul 2, 2004 |
7515431 |
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Current U.S.
Class: |
361/752; 361/800;
361/790 |
Current CPC
Class: |
H04M
1/0202 (20130101); H04M 1/026 (20130101); Y10T
29/4902 (20150115); Y10T 29/49002 (20150115); H04M
1/0277 (20130101) |
Current International
Class: |
H05K
5/00 (20060101) |
Field of
Search: |
;361/752,790,797,800,715
;312/223 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
"Maxtor OneTouch II Fire Wire and USB", Maxtor.com, Dec. 1, 2004,
http://www.maxtor.com/portal/site/Maxtor/menuitem.ba88f6d7cf664718376049b-
2913460. cited by other .
"Maxtor OneTouch USB One Touch Family", Maxtor.com, Dec. 1, 2004,
http://www.maxtor.com/portal/site/Maxtor/menuitem.ba88f6d7cf664718376049b-
2913460. cited by other .
"CoolerMaster Wave Master Black Aluminum Case Review", PCStats.com,
Dec. 1, 2004,
http://www.pcstats.com/articleview.cfm?articleID=1552. cited by
other .
U.S. Appl. No. 10/643,256, filed Aug. 18, 2003. cited by other
.
Office Action mailed Nov. 16, 2005 from U.S. Appl. No. 10/884,172.
cited by other .
Final Office Action mailed May 4, 2006 from U.S. Appl. No.
10/884,172. cited by other .
Office Action mailed Jul. 27, 2007 from U.S. Appl. No. 10/884,172.
cited by other .
Final Office Action mailed Dec. 28, 2007 from U.S. Appl. No.
10/884,172. cited by other .
Office Action mailed Aug. 6, 2008 from U.S. Appl. No. 10/884,172.
cited by other .
Notice of Allowance mailed Dec. 1, 2008 from U.S. Appl. No.
10/884,172. cited by other .
Supplemental Notice of Allowability mailed Feb. 4, 2009 from U.S.
Appl. No. 10/884,172. cited by other .
U.S. Appl. No. 29/196,832, filed Jan. 5, 2004. cited by other .
Notice of Allowance dated Sep. 8, 2009 in U.S. Appl. No.
12/395,570. cited by other.
|
Primary Examiner: Bui; Hung S
Attorney, Agent or Firm: Beyer Law Group LLP
Parent Case Text
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent
application Ser. No. 10/884,172, filed Jul. 2, 2004 now U.S. Pat.
No. 7,515,431 and entitled "HANDHELD COMPUTING DEVICE" which is
hereby incorporated herein by reference.
This application is related to the following U.S. Patent
Applications, which are hereby incorporated herein by
reference:
Application Ser. No.: 29/196,832, filed on Jan. 5, 2004 and
entitled "MEDIA DEVICE"
Application Ser. No. 10/643,256, filed on Aug. 18, 2003 and
entitled "MOVABLE TOUCHPAD WITH ADDED FUNCTIONALITY"
Application Ser. No. 10/188,182, filed on Jul. 1, 2002 and entitled
"TOUCHPAD FOR HANDHELD DEVICE"
Application Ser. No. 10/722,948, filed on Nov. 25, 2003 and
entitled "TOUCHPAD FOR HANDHELD DEVICE"
Application Ser. No. 10/423,490, filed on Apr. 25, 2003 and
entitled "MEDIA PLAYER SYSTEM"
Application Ser. No. 09/821,784, filed on Mar. 28, 2001 and
entitled "COMPUTER ENCLOSURE"
Application Ser. No. 10/928,780, filed on Aug. 27, 2004 and
entitled "COMPUTER ENCLOSURE"
Application Ser. No.: 29/237,090, filed on Aug. 24, 2005 and
entitled "MEDIA DEVICE"
Application Ser. No.: 29/237,096, filed on Aug. 24, 2005 and
entitled "MEDIA DEVICE"
Application Ser. No. 09/821,784, filed on Mar. 28, 2001 and
entitled "COMPUTER ENCLOSURE"
Application Ser. No. 10/928,780, filed on Aug. 27, 2004 and
entitled "COMPUTER ENCLOSURE"
Claims
What is claimed is:
1. A portable computing device capable of wireless communications,
the portable computing device comprising: an integral and
substantially seamless enclosure that surrounds and protects the
internal operational components of the portable computing device,
the enclosure extending along a longitudinal axis and defining an
internal lumen that is sized and dimensioned for slidable receipt
of the internal operational components, the enclosure having a
substantially uniform cross-section along a longitudinal axis and
including a structural wall defining a shape or form of the
portable computing device and being formed from a radio-transparent
material that permits wireless communications therethrough, wherein
the lumen engages with a locking feature of an operational
component to secure the operational component to the tube when the
operational component is in its desired position within the
lumen.
2. The portable computing device as recited in claim 1 wherein the
portable computing device uses radio frequency in wireless
communications and wherein the radio-transparent material is a
ceramic material.
3. The portable computing device as recited in claim 2 wherein the
ceramic material is zirconia.
4. The portable computing device as recited in claim 2 wherein the
ceramic material is alumina.
5. The portable computing device as recited in claim 1 wherein the
enclosure includes a tube like main body that is extruded in its
entirety with the radio-transparent material.
6. The portable computing device as recited in claim 1 wherein the
portable computing device is a handheld computing device.
7. The portable computing device as recited in claim 6 wherein the
handheld computing device is a cell phone.
8. The portable computing device as recited in claim 6 wherein the
handheld computing device is a media player.
9. A portable computing device, comprising: an elongated and
substantially seamless enclosure that surrounds and protects the
internal operational components of the portable computing device,
the enclosure including a structural wall defining a shape or form
of the portable computing device and being formed from a
radio-transparent material, the enclosure defining an internal
lumen that is sized and dimensioned for slidable receipt of the
internal operational components, wherein the lumen engages with a
locking feature of an operational component to secure the
operational component to the tube when the operational component is
in its desired position within the lumen.
10. The portable computing device as recited in claim 9 wherein the
radio-transparent material is a ceramic material.
11. The portable computing device as recited in claim 10 wherein
the ceramic material is zirconia.
12. The portable computing device as recited in claim 9 wherein a
significant portion of the entire enclosure is formed from a
radio-transparent material.
13. The portable computing device as recited in claim 9 wherein the
enclosure includes an extruded tube of the ceramic material, and
end caps that close the ends of the extruded tube of ceramic
material.
14. A handheld computing device, comprising: a seamless integral
extruded tube formed from a radio-transparent material and
extending along a longitudinal axis, the seamless integral extruded
tube having a first open end and a second open end opposite the
first open end, the seamless tube defining an internal lumen which
is sized and dimensioned for insertion of operational components of
the handheld computing device, wherein the lumen engages with a
locking feature of an operational component to secure the
operational component to the tube when the operational component is
in its desired position within the lumen.
15. The handheld computing device as recited in claim 14 wherein
the lumen includes internal rails for guiding the operational
components to their desired position within the lumen.
16. The handheld computing device as recited in claim 14 wherein
the seamless tube has a substantially planar front surface, the
planar front surface being configured to present a user interface
sub system of the handheld computing device, the open ends being
configured to receive the user interface sub system therethrough
during assembly of the handheld computing device.
17. The handheld computing device as recited in claim 16 wherein
the lumen includes internal rails for guiding the operational
components to their desired position within the lumen, and wherein
the internal rails being configured to locate the user interface
sub system in its desired position relative to the planar front
surface of the enclosure during assembly of the handheld
device.
18. The handheld computing device as recited in claim 16 wherein
the user interface sub system includes a display and a touch
pad.
19. The handheld computing device as recited in claim 14 wherein
the radio-transparent material is a ceramic material.
20. The handheld computing device as recited in claim 19 wherein
the ceramic material is zirconia.
21. The handheld computing device as recited in claim 14 further
comprising end caps at the first and second ends of the seamless
tube, the end caps and seamless tube working together to fully
surround the internal operational components of the handheld
computing device.
22. The handheld computing device as recited in claim 14 wherein
the handheld computing device is a music player.
23. A portable computing device capable of wireless communications,
the portable computing device comprising: an integral and
substantially seamless extruded enclosure that surrounds and
protects the internal operational components of the portable
computing device, the enclosure including a structural wall
defining a shape or form of the portable computing device and being
formed from a material other than plastic that permits wireless
communications therethrough and the enclosure defines an internal
lumen engages with a locking feature of an operational component to
secure the operational component to the tube when the operational
component is in its desired position within the lumen; and an
internal antenna disposed inside the enclosure.
24. The portable computing device as recited in claim 23 wherein
the portable computing device uses radio frequency in wireless
communications and wherein the structural wall is formed from a
ceramic material that is radio-transparent.
25. The portable computing device as recited in claim 24 wherein
the ceramic material is zirconia.
26. The portable computing device as recited in claim 23 wherein
the structural wall constitutes a substantial portion of the entire
enclosure.
27. The portable computing device as recited in claim 23 wherein
the structural wall constitutes one or more walls of the entire
enclosure.
28. The portable computing device as recited in claim 23 wherein
the structural wall constitutes two or more walls of the entire
enclosure.
29. The portable computing device as recited in claim 23 wherein
the enclosure only includes a main body and a pair of end caps, the
structural wall being at least a portion of the main body.
30. The portable computing device as recited in claim 29 wherein
the structural wall constitutes the entire main body.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to portable computing
devices. More particularly, the present invention relates to
enclosures of portable computing devices and methods of assembling
portable computing devices.
2. Description of the Related Art
In recent years, portable computing devices such as laptops, PDAs,
media players, cellular phones, etc., have become small, light and
powerful. One factor contributing to this phenomena is in the
manufacturer's ability to fabricate various components of these
devices in smaller and smaller sizes while in most cases increasing
the power and or operating speed of such components. Unfortunately,
the trend of smaller, lighter and powerful presents a continuing
design challenge in the design of some components of the portable
computing devices.
One design challenge associated with the portable computing devices
is the design of the enclosures used to house the various internal
components of the portable computing devices. This design challenge
generally arises from two conflicting design goals--the
desirability of making the enclosure lighter and thinner, and the
desirability of making the enclosure stronger and more rigid. The
lighter enclosures, which typically use thinner plastic structures
and fewer fasteners, tend to be more flexible and therefore they
have a greater propensity to buckle and bow when used while the
stronger and more rigid enclosures, which typically use thicker
plastic structures and more fasteners, tend to be thicker and carry
more weight. Unfortunately, increased weight may lead to user
dissatisfaction, and bowing may damage the internal parts of the
portable computing devices.
Furthermore, in most portable computing devices, the enclosures are
mechanical assemblies having multiple parts that are screwed,
bolted, riveted, or otherwise fastened together at discrete points.
For example, the enclosures typically have included an upper casing
and a lower casing that are placed on top of one another and
fastened together using screws. These techniques typically
complicate the housing design and create aesthetic difficulties
because of undesirable cracks, seams, gaps or breaks at the mating
surfaces and fasteners located along the surfaces of the housing.
For example, a mating line surrounding the entire enclosure is
produced when using an upper and lower casing. Not only that, but
assembly is often a time consuming and cumbersome process. For
example, the assembler has to spend a certain amount of time
positioning the two parts and attaching each of the fasteners.
Furthermore, assembly often requires the assembler to have special
tools and some general technical skill.
Another design challenge is in techniques for mounting structures
within the portable computing devices. Conventionally, the
structures have been laid over one of the casings (upper or lower)
and attached to one of the casings with fasteners such as screws,
bolts, rivots, etc. That is, the structures are positioned in a
sandwich like manner in layers over the casing and thereafter
fastened to the casing. This methodology suffers from the same
drawbacks as mentioned above, i.e., assembly is a time consuming
and cumbersome.
In view of the foregoing, there is a need for improved enclosures
for portable computing devices. Particularly, enclosures that are
more cost effective, smaller, lighter, stronger and aesthetically
more pleasing than current enclosure designs. In addition, there is
a need for improvements in the manner in which structures are
mounted within the enclosures. For example, improvements that
enable structures to be quickly and easily installed within the
enclosure, and that help position and support the structures in the
enclosure.
SUMMARY OF THE INVENTION
The invention relates, in one embodiment, to a portable computing
device capable of wireless communications. The portable computing
device includes an enclosure that surrounds and protects the
internal operational components of the portable computing device.
The enclosure includes a structural wall formed from a ceramic
material that permits wireless communications therethrough. The
wireless communications may for example correspond to RF
communications, and further the ceramic material may be
radio-transparent thereby allowing RF communications
therethrough.
The invention relates, in another embodiment, to a portable
computing device. The portable computing device includes an
enclosure that surrounds and protects the internal operational
components of the portable computing device. The enclosure includes
a structural wall formed from a ceramic material. In some cases,
multiple structural walls are formed from the ceramic material. In
other cases, a significant portion of the entire enclosure is
formed from the ceramic material.
The invention relates, in another embodiment, to a handheld
computing device. The handheld computing device includes a seamless
tube formed from a ceramic material and extending along a
longitudinal axis. The seamless tube has a first open end and a
second open end opposite the first open end. The elongated seamless
tube defines an internal lumen which is sized and dimensioned for
insertion of operational components of the handheld computing
device.
The invention relates, in another embodiment, to a portable
computing device capable of wireless communications. The portable
computing device includes an enclosure that surrounds and protects
the internal operational components of the portable computing
device. The enclosure includes a structural wall formed from a
material other than plastic that permits wireless communications
therethrough. The portable computing device also includes an
internal antenna disposed inside the enclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be readily understood by the following detailed
description in conjunction with the accompanying drawings, wherein
like reference numerals designate like structural elements, and in
which:
FIG. 1 is an exploded perspective diagram of an electronic device,
in accordance with one embodiment of the present invention.
FIG. 2 is a perspective diagram of a handheld computing device, in
accordance with one embodiment of the present invention.
FIG. 3A is a diagram of an assembled hand held computing device, in
accordance with one embodiment of the present invention.
FIG. 3B is a diagram of the hand held computing device of FIG. 3A
in its unassembled form, in accordance with one embodiment of the
present invention.
FIG. 4 is top view diagram, in cross section, of an assembled hand
held computing device, in accordance with one embodiment of the
present invention.
FIG. 5 is bottom view diagram, in cross section, of the assembled
hand held computing device, in accordance with one embodiment of
the present invention.
FIGS. 6A-6C show the insertion and mounting of an input assembly
inside a seamless enclosure, in accordance with one embodiment of
the present invention.
FIGS. 7A and 7B show a bottom plate in its unassembled and
assembled positions, in accordance with one embodiment of the
present invention.
FIG. 8 is a diagram of the audio subassembly, in accordance with
one embodiment of the present invention.
FIG. 9A is a front perspective view of a seamless enclosure, in
accordance with one embodiment of the present invention.
FIG. 9B is a rear perspective view of a seamless enclosure, in
accordance with one embodiment of the present invention.
FIG. 9C is a front view of a seamless enclosure, in accordance with
one embodiment of the present invention.
FIG. 9D is a rear view of a seamless enclosure, in accordance with
one embodiment of the present invention.
FIG. 9E is a top view of a seamless enclosure, in accordance with
one embodiment of the present invention.
FIG. 9F is a bottom view diagram of a seamless enclosure, in
accordance with one embodiment of the present invention.
FIG. 9G is a right side view of a seamless enclosure, in accordance
with one embodiment of the present invention.
FIG. 9H is a left side view of a seamless enclosure, in accordance
with one embodiment of the present invention.
FIG. 10 is a method of manufacturing an electronic device, in
accordance with one embodiment of the present invention.
FIG. 11 is a method of manufacturing a ceramic enclosure, in
accordance with one embodiment of the present invention.
FIG. 12 is a diagram of an enclosure, in accordance with one
embodiment of the present invention.
FIG. 13 is a diagram of an enclosure, in accordance with one
embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The invention generally pertains to portable computing devices and
more particularly to components of and methods for assembling
portable computing devices.
One aspect of the invention relates to a seamless enclosure that
includes open ends for inserting the internal components of the
portable computing devices through the open ends of the seamless
enclosure. The seamless enclosure may include internal rails which
serve as a guide for positioning and supporting the internal
components in their assembled position within the seamless
enclosure. The seamless enclosure may for example be formed via an
extrusion process from metals such as aluminum or ceramics such as
zirconia or alumina.
Another aspect of the invention relates to a planar retaining
plate, which serves as a multi-positional reference surface to
various components of the portable computing devices. The retaining
plate may for example be assembled within the lumen of the seamless
enclosure to provide a reference surface to internal and external
parts of the portable computing device. Another aspect of the
invention relates to assemblies capable of flexing in order to
align interfacing parts. For example, aligning a plate within the
lumen of the seamless enclosure.
Yet another aspect of the invention relates to a method of
manufacturing a portable computing device. The method may include
extruding a tube, cutting the tube to a desired length, forming one
or more access openings in the face of the tube, inserting a user
interface assembly into the tube, and thereafter locating and
supporting the user interface assembly behind the access
openings.
These and other embodiments of the invention are discussed below
with reference to FIGS. 1-13. However, those skilled in the art
will readily appreciate that the detailed description given herein
with respect to these figures is for explanatory purposes as the
invention extends beyond these limited embodiments.
FIG. 1 is an exploded perspective diagram of an electronic device
50, in accordance with one embodiment of the present invention. The
device 50 may be sized for one-handed operation and placement into
small areas such as a pocket, i.e., the device 50 can be a handheld
pocket sized electronic device. By way of example, the electronic
device 50 may correspond to a computer, media device,
telecommunication device and/or the like.
The device 50 includes a housing 52 that encloses and supports
internally various electrical components (including for example
integrated circuit chips and other circuitry) to provide computing
operations for the device 50. The housing 52 also defines the shape
or form of the device 50. That is, the contour of the housing 52
may embody the outward physical appearance of the device 50. The
housing 52 generally includes a main body 54 in the form of an
integral tube. By integral, it is meant that the main body is a
single complete unit. By being integrally formed, the main body is
structurally stronger than conventional housings, which include two
parts that are fastened together. Furthermore, unlike conventional
housings that have a seam between the two parts, the main body has
a substantially seamless appearance. Moreover, the seamless housing
prevents contamination and is more water resistant than
conventional housings.
Because of the tube like configuration, the main body 54 defines a
cavity 56 therethrough between a first open end 58 and second open
end 60 located opposite the first open end 58. The main body 54
also includes one or more windows 62, which provide access to the
electrical components, particularly the user interface elements,
when they are assembled inside the cavity 56 of the main body
54.
In order to seal the main body 54, the housing 52 additionally
includes a pair of end caps 64A and 64B. Each of the end caps 64 is
configured to cover one of the open ends 58 or 60 thereby forming a
fully enclosed housing system. The end caps 64 may be formed from
similar or different materials as the main body 54. Furthermore,
the end caps 64 may be attached to the main body 54 using a variety
of techniques, including but not limited to, fasteners, glues,
snaps, and/or the like. In some cases, the end caps 64 may be
positioned on the surface of the open ends 58 and 60. If so, they
typically have the same shape as the outer periphery of the main
body 54. In order to eliminate gaps, cracks or breaks on the front
and side surfaces, the end caps 64 may alternatively be placed
inside the cavity 56 at each of the ends. In this arrangement, the
outer periphery of the end cap 64 generally matches the inner
periphery of the main body 54. This implementation is typically
preferred in order to form a housing 52 with a uniform and seamless
appearance, i.e., no breaks when looking directly at the front,
back or side of the housing.
The cross sectional shape, including both the outer and inner
shapes, of the main body 54 may be widely varied. They may be
formed from simple or intricate shapes whether rectilinear and/or
curvilinear. For hand held devices, it is typically preferred to
use a shape that better fits the hand (e.g., form fits). By way of
example, a rectangle with curved edges or an oval or pill shaped
cross section having curvature that more easily receives the hand
may be used. It should be noted that the inner cross sectional
shape may be the same or different from the external cross
sectional shape of the main body. For example, it may be desirable
to have a pill shaped external and a rectangularly shaped interior,
etc. In addition, although not a requirement, the front surface of
the main body 54 may be substantially planar for placement of the
user interface of the device 50.
The device 50 also includes one or more electronic subassemblies
66. The subassemblies 66 each include a carrier 68 and one or more
operational components 70 of the electronic device 50. The carrier
68 provides a structure for carrying the operational components 70
and supporting them when assembled inside the housing 52. By way of
example, the carrier 68 may be formed from plastics, metals and/or
a printed circuit board (PCB). The operational components 70, on
the other hand, perform operations associated with the computing
device 50. The operational components 70 may for example include
user interface elements 70A and/or circuit elements 70B. The user
interface elements 70A allow a user to interact with the computing
device 50. By way of example, the user interface elements 70A may
correspond to a display and/or an input device such as a keypad,
touch pad, touch screen, joystick, trackball, buttons, switches
and/or the like. The circuit components 70B, on the other hand,
perform operations such as computing operations for the computing
device 50. By way of example, the computing components 70B may
include a microprocessor, memory, hard drive, battery, I/O
connectors, switches, power connectors, and/or the like.
During assembly, the subassemblies 66 are positioned inside the
cavity 56 of the main body 54. In particular, the subassemblies 66
are inserted into one of the open ends 58 or 60 of the main body 54
mainly along a longitudinal axis 74 of the main body 54 to their
desired position within the housing 52. Once positioned inside the
cavity 56, the end caps 64 of the housing 52 may be attached to the
main body 54 in order to fully enclose the housing 52 around the
subassemblies 66. In most cases, the user interface elements 70A
are positioned relative to the window opening 62 so that a user may
utilize the user interface elements 70A. By way of example, the
window 62 may allow viewing access to a display or finger access to
a touch pad or button.
In order to more efficiently assemble the electronic subassemblies
66 inside the cavity 56, the device 50 may include an internal rail
system 78 disposed inside the cavity 56 of the main body 54. In
most cases, the internal rail system 78 is integrally formed with
the main body 54, i.e., formed as a single part. The internal rail
system 78 is configured to receive the various subassemblies 66 and
guide them to their desired position within the main body 54 when
the subassemblies 66 are inserted through one of the open ends 58
or 60. The internal rail system 78 enables the subassemblies 66 to
be easily and quickly assembled within the device 50. For example,
the rail system 78 provides for insertion (or removal) with minimal
effort and without tools. The internal rail system 78 also helps
support and store the subassemblies 66 in an organized manner
within the device 50. By way of example, the rail system 78 may
store the subassemblies 66 in a stacked parallel arrangement
thereby using available space more efficiently.
In the illustrated embodiment, the rail system 78 includes at least
one set of opposed rails 80, each of which extends longitudinally
through the cavity 56 and each of which protrudes from the inner
sides of the main body 54. The rails 80 are configured to receive
the subassembly 66 and cooperate to guide subassemblies 66 to their
desired position within the housing 52. The internal rails 80
generally allow the subassemblies 66 to be slid into the cavity 56
through the open ends 58 or 60 following the longitudinal axis 74
of the main body 54. That is, the subassemblies 66 and more
particularly the carrier 68 are capable of sliding in and out of
the housing 52 along one or more surfaces of the rails 80.
The portion of the subassemblies 66 that engages the rails 80 may
be a surface of the subassemblies or alternatively one or more
posts or mounts that extend outwardly from the subassemblies 66.
Furthermore, the reference surfaces for the opposed rails 80 may be
positioned in the same plane or they may be positioned in different
planes. The configuration generally depends on the configuration of
the subassemblies 66. By way of example, in some cases, the
subassemblies 66 may have a cross section that is stepped rather
than completely planar. In cases such as these, the opposed rails
80 have references surfaces in different planes in order to
coincide with the stepped cross section. Moreover, although
typically continuous between the ends, each of the rails 80 may be
segmented or include removed portions as for example at the ends
for placement of the flush mounted end caps.
The width of the rails 80 may be widely varied. For example, they
may be one integral piece that extends entirely from one side to
the other, or they may be separate pieces with a gap located
therebetween (as shown). The position and cross sectional
dimensions and shapes of each of the rails may also be widely
varied. The size and shape as well as the position of the rails 80
generally depends on the configuration of the sub assemblies 66.
The rails 80 may have the same shape and size or they may have
different shape and size. In most cases, the size and shape is a
balance between keeping them as small as possible (for weight and
space requirements) while providing the required reference surface
and ample support to the subassemblies 66.
To elaborate, the rails 80 define one or more channels 82 that
receive the one or more subassemblies 66. In the illustrated
embodiment, the rails 80 along with the main body 54 define a pair
of channels, particularly an upper channel 82A and a lower channel
82B. The upper channel 82A receives a first subassembly 66A and the
lower channel 8B receives a second subassembly 66B. It should be
noted, however, that this is not a limitation and that additional
sets of rails 80 may be used to produce additional channels 82. It
should also be noted that although only one subassembly 66 is shown
for each channel 82 this is not a requirement and that more than
one subassembly 66 may be inserted into the same channel 82.
Moreover, it should be noted that the subassemblies are not limited
to being fully contained with a single channel and that portions of
a subs assembly may be positioned in multiple channels. For
example, the second subassembly 66B, which is positioned in the
lower channel 82B, may include a protruding portion that is
positioned through the rails 80 and into the upper channel 82A.
The channels 82 generally include an entry point and a final point.
The entry point represents the area of the channel 82 that
initially receives the subassemblies 66, i.e., the area proximate
the ends of the main body 54. The final point, on the other hand
represents the area of the channel 82 that prevents further sliding
movement. The final point may for example set the final mount
position of the sub assemblies 66 within the housing 52. The final
point may for example correspond to an abutment stop. The abutment
stop may be integral with the main body 54 or a separate component.
By way of example, the abutment stop may correspond to one more
posts that are mounted inside the cavity 56 on the inside surface
of the main body 54 at a predetermined distance along the
longitudinal axis 74.
In order to prevent the subassemblies 66 from sliding once
assembled, the interface between the subassemblies 66 and housing
52 may include a locking or securing mechanism. The locking
mechanism 86 generally consists of two parts, a housing side
locking feature and a subassembly side locking feature that are
cooperatively positioned so that when the subassembly 66 is
inserted into the housing 52, the locking features engage with one
another thus holding the subassembly 66 in its desired position
within the housing 52. In most cases, the locking features are
configured to provide quick and easy assembly of the subassembly
into the housing without the use of tools. The locking features may
correspond to snaps, friction couplings, detents, flexures and/or
the like. Alternatively or additionally, the assemblies 66 may be
attached to the main body 54 with fasteners or adhesives.
In the illustrated embodiment, the subassemblies 66 each include a
flexure tab 88 that engages a recess 90 located on an inner surface
of the main body 54. When the subassembly 66 is slid into the
housing 52, the tab 88 snaps into the recess 90 thereby securing
the subassembly 66 at a predetermined position along the
longitudinal axis 74. That is, because the tabs 88 flex, they allow
the subassemblies 66 to pass when pushed into the cavity 76. When
the subassemblies 66 pass over the recess 90, the tabs 88 resume
their natural position thereby trapping the subassemblies 66 in the
channel 82 between the locking tab/recess 88/90 and the abutment
stop at the end of the channel 82. Using this arrangement, the
subassemblies 66 are prevented from sliding out of the channels 82
on their own. In order to remove the subassembly 66, a user simply
lifts the tab 88 away from the recess 90 while pulling on the
subassembly 66. The recess 90 and abutment stop may cooperate to
set the final position of the subassembly 66 in the cavity 56 of
the main body 54. For example, the recess and abutment stop may be
configured to position the user interface elements 70A directly
behind the window opening 62 so that a user has full access to the
user interface elements 70A.
In accordance with one embodiment, the main body 54, which may
include the internal rails 80 (or other internal features), is
formed via an extrusion process. The extrusion process is capable
of producing an integral tube without seams, crack, breaks, etc. As
is generally well known, extrusion is a shaping process where a
continuous work piece is produced by forcing molten or hot material
through a shaped orifice, i.e., the extrusion process produces a
length of a particular cross sectional shape. The cross sectional
shape of the continuous or length of work piece is controlled at
least in part on the shaped orifice. As the shaped work piece exits
the orifice, it is cooled and thereafter cut to a desired length.
As should be appreciated, the extrusion process is a continuous
high volume process that produces intricate profiles and that
accurately controls work piece dimensions (which can be a necessity
for smaller parts). Furthermore, because extrusion has low tooling
costs, it is relatively in expensive when compared to other forming
or manufacturing processes.
The main body 54 may be formed from a variety of extrudable
materials or material combinations including but not limited to
metals, metal alloys, plastics, ceramics and/or the like. By way of
example, the metals may correspond to aluminum, titanium, steel,
copper, etc., the plastic materials may correspond to
polycarbonate, ABS, nylon, etc, and the ceramic materials may
correspond to alumina, zirconia, etc. Zirconia may for example
correspond to zirconia oxide.
The material selected generally depends on many factors including
but not limited to strength (tensile), density (lightweight),
strength to weight ratio, Young's modulus, corrosion resistance,
formability, finishing, recyclability, tooling costs, design
flexibility, manufacturing costs, manufacturing throughput,
reproduceability, and/or the like. The material selected may also
depend on electrical conductivity, thermal conductivity, radiowave
transparency, combustability, toxicity, and/or the like. The
material selected may also depend on aesthetics including color,
surface finish, weight, etc.
In one particular embodiment, the main body 54 with or without the
internal rails 80 is formed from an extruded aluminum tube. Some of
the reasons for using aluminum over other materials is that it is
light weight and structurally stronger (e.g., it has very good
mechanical properties and strength to weight ratio). This is
especially important for hand held devices. Other reasons for using
aluminum include: reduced tooling costs (e.g., injection moldings
can be cost prohibitive), its easily formable and extruded in a
wide variety of shapes including hollow parts, easily machinable
thus making it easy to alter the part after the extrusion process,
provides a near net shape, offers superior corrosion resistance, it
has high scrap value and is routinely reprocessed to generate new
extrusions, it can be finished using a variety of methods including
mechanical and chemical prefinishes, anodic coatings, paints and
electroplated finishes.
In another embodiment, the main body 54 with or without the
internal rails 80 is formed from an extruded ceramic tube. In one
implementation, the ceramic material is alumina. In another
implementation, the ceramic material is zirconia. Some of the
reasons for using ceramics over other materials is that it is
structurally strong, stiff and radio transparent. This is
especially important for wireless hand held devices that include
antennas internal to the enclosure. Radio transparency allows the
wireless signals to pass through the enclosure and in some cases
enhances these transmissions. Other reasons for using ceramics is
that they are highly scratch resistant, have color embedded in it
(no paint or coatings), can be made into a wide variety of colors,
and provides a variety of surface finishes including smooth and
rough. Furthermore, the density of ceramics is typically higher
than other materials therefore their weight is higher for the same
sized part. This additional weight makes the handheld device feel
more robust and it makes the device exude greater quality.
It should be noted that ceramics have been used in a wide variety
of products including electronic devices such as watches, phones,
and medical instruments. In all of these cases, however, the
ceramic material have not been used as structural components. In
most of these cases they have been used as cosmetic accoutrements.
It is believed up till now ceramic materials have never been used
as a structural element including structural frames, walls or main
body of a consumer electronic device, and more particularly an
enclosure of a portable electronic device such as a media player or
cell phone.
FIG. 2 is a perspective diagram of a handheld computing device 100,
in accordance with one embodiment of the present invention. By way
of example, the computing device 100 may generally correspond to
the device 50 shown and described in FIG. 1. The computing device
100 is capable of processing data and more particularly media such
as audio, video, images, etc. By way of example, the computing
device 100 may generally correspond to a music player, game player,
video player, camera, cell phone, personal digital assistant (PDA),
and/or the like. With regards to being handheld, the computing
device 100 can be operated solely by the user's hand(s), i.e., no
reference surface such as a desktop is needed. In some cases, the
handheld device is sized for placement into a pocket of the user.
By being pocket sized, the user does not have to directly carry the
device and therefore the device can be taken almost anywhere the
user travels (e.g., the user is not limited by carrying a large,
bulky and heavy device). In the illustrated embodiment, the
computing device 100 is a pocket sized hand held music player that
allows a user to store a large collection of music. By way of
example, the music player may correspond to the iPod series MP3
players, including for example the iPod mini and iPod Nano
manufactured by Apple Computer of Cupertino, Calif.
As shown, the computing device 100 includes a housing 102 that
encloses and supports internally various electrical components
(including integrated circuit chips and other circuitry) to provide
computing operations for the device. The integrated circuit chips
and other circuitry may include a microprocessor, hard drive,
Read-Only Memory (ROM), Random-Access Memory (RAM), a battery, a
circuit board, and various input/output (I/O) support circuitry. In
addition to the above, the housing 102 may also define the shape or
form of the device 100. In this particular embodiment, the housing
102 extends longitudinally and has a pill like cross section. The
size and shape of the housing 102 is preferably dimensioned to fit
comfortably within a users hand. In one particular embodiment, the
housing is formed from an extruded material such as aluminum
thereby providing a seamless look along the length of the device
100. That is, unlike conventional housings, the housing 102,
particularly the main body, does not include any breaks between the
top and bottom ends thereby making it stronger and more
aesthetically pleasing.
The computing device 100 also includes a display screen 104. The
display screen 104, which is assembled within the housing 102 and
which is visible through an opening 106 in the housing 102, is used
to display a graphical user interface (GUI) as well as other
information to the user (e.g., text, objects, graphics). By way of
example, the display screen 104 may be a liquid crystal display
(LCD). In some cases, the housing 102 may include a window, which
is positioned in the opening in front of the display in order to
protect the display from damage. The window is typically formed
from a clear material such as clear polycarbonate plastic.
The computing device 100 also includes one or more input devices
108 configured to transfer data from the outside world into the
computing device 100. The input devices 108 may for example be used
to perform tracking/scrolling, to make selections or to issue
commands in the computing device 100. By way of example, the input
devices 108 may correspond to keypads, joysticks, touch screens,
touch pads, track balls, wheels, buttons, switches, and/or the
like. In the illustrated embodiment, the computing device 100
includes a touch pad 108A and one or more buttons 108B, which are
assembled within the housing 102 and which are accessible through a
second opening 110 in the housing 102.
The touch pad 108A generally consists of a touchable outer surface
111 for receiving a finger for manipulation on the touch pad 100A.
Although not shown, beneath the touchable outer surface 111 is a
sensor arrangement. The sensor arrangement includes a plurality of
sensors that are configured to activate as the finger passes over
them. In the simplest case, an electrical signal is produced each
time the finger passes a sensor. The number of signals in a given
time frame may indicate location, direction, speed and acceleration
of the finger on the touch pad, i.e., the more signals, the more
the user moved his or her finger. In most cases, the signals are
monitored by an electronic interface that converts the number,
combination and frequency of the signals into location, direction,
speed and acceleration information. This information may then be
used by the device 100 to perform the desired control function on
the display screen 104.
The position of the touch pad 108A relative to the housing 102 may
be widely varied. For example, the touch pad 108A may be placed at
any external surface (e.g., top, side, front, or back) of the
housing 102 that is accessible to a user during manipulation of the
device 100. In most cases, the touch sensitive surface 101 of the
touch pad 108A is completely exposed to the user. In the
illustrated embodiment, the touch pad 108A is located in a lower,
front area of the housing 102. Furthermore, the touch pad 108A may
be recessed below, level with, or extend above the surface of the
housing 102. In the illustrated embodiment, the touch sensitive
surface 111 of the touch pad 108A is substantially flush with the
external surface of the housing 102.
The shape of the touch pad 108A may also be widely varied. For
example, the touch pad 108A may be circular, rectangular, square,
oval, triangular, and the like. In the illustrated embodiment, the
touch pad 108A is circular. Circular touch pads allow a user to
continuously swirl a finger in a free manner, i.e., the finger can
be rotated through 360 degrees of rotation without stopping.
Furthermore, the user can rotate his or her finger tangentially
from all sides thus giving it more range of finger positions. For
example, when the device 100 is being held, a left handed user may
choose to use one portion of the touch pad 108A while a right
handed user may choose to use another portion of the touch pad
108A. More particularly, the touch pad is annular, i.e., shaped
like or forming a ring. When annular, the inner and outer perimeter
of the shaped touch pad defines the working boundary of the touch
pad.
The buttons 108B are configured to provide one or more dedicated
control functions for making selections or issuing commands
associated with operating the device 100. By way of example, in the
case of a music player, the button functions may be associated with
opening a menu, playing a song, fast forwarding a song, seeking
through a menu and the like. In most cases, the button functions
are implemented via a mechanical clicking action although they may
also be associated with touch sensing similar to the touch pad
108A. The position of the buttons 108B relative to the touch pad
108A may be widely varied. For example, they may be next to one
another (center or peripheral), spaced apart or integrated into a
single unit. Several touch pad/button arrangements, which may be
used in the device 100, are described in greater detail in pending
patent application Ser. Nos. 10/643,256, 10/188,182, 10/722,948,
which are all herein incorporated by reference.
The computing device 100 also includes one or more switches 112
including power switches, hold switches, and the like. The power
switch is configured to turn the device 100 on and off, and the
hold switch is configured to activate or deactivate the touch pad
108A and/or buttons 108B. This is generally done to prevent
unwanted commands by the touch pad 108A and/or buttons 108B, as for
example, when the device 100 is stored inside a user's pocket. Like
the touch pad 108A and buttons 108B, the switches 112 are
accessible through a third opening 114 in the housing 102.
The device 100 may also include one or more connectors 116 for
transferring data and/or power to and from the device 100. In the
illustrated embodiment, the device 100 includes an audio jack 116A,
a data port 116B and a power port 116C. The audio jack 116A allows
audio information to be outputted from the device 100. The data
port 116B allows data to be transmitted and received to and from a
host device such as a general purpose computer (e.g., desktop
computer, portable computer). The data port 116B may be used to
upload or down load audio, video and other image data to and from
the device 100. For example, the data port 116B may be used to
download songs and play lists, audio books, ebooks, photos, and the
like into the storage mechanism of the computing device 100. The
power port 116C, on the other hand, allows power to be delivered to
the computing device 100. In some cases, the data port 116B may
serve as both a data and power port thus replacing a dedicated
power port 116C. A data port such as this is described in greater
detail in pending U.S. Pat. Application Ser. No. 10/423,490, which
is herein incorporated by reference.
FIGS. 3A and 3B are diagrams of a hand held computing device 150,
in accordance with one embodiment of the present invention. FIG. 3A
is perspective diagram showing the computing device 150 in its
assembled form, while FIG. 3B is an exploded perspective diagram
showing the computing device 150 in its unassembled form. The
computing device 150 may generally correspond to the computing
device 100 shown and described in FIG. 2.
The computing device 150 includes a housing 152, which serves to
support the internal components of the computing device 150 in
their assembled position within the device 150. The housing 152
includes several components including a seamless enclosure 154, a
bottom end cap 156 and a top end cap 158. The seamless enclosure
154 extends along a longitudinal axis 160, and includes an internal
lumen 162 which is sized and dimension for receipt of the internal
components of the computing device 150 through a first open end 164
and a second open end 166 opposite the first open end 164. The end
caps 156 and 158 cover the open ends 164 and 166 of the seamless
enclosure 154 in order to provide a fully contained housing 152.
Although the end caps 156 and 158 can be applied in a variety or
ways, in this particular embodiment, each of the end caps 156 and
158 includes a shape that coincides with the internal shape of the
seamless enclosure 154 such that they may be inserted into the open
ends, i.e., the outer periphery of the end caps 156, 158 matches
the inner periphery of the lumen 162. Furthermore, the end caps 156
and 158 are positioned to be flush with the bottom 170 and top
surfaces 172 of the seamless enclosure 154 thereby forming a
housing 152 with a substantially uniform appearance.
In order to help guide at least a portion of the internal
components to their desired position within the seamless enclosure
154, the seam less enclosure 154 may include an internal rail
system 176 including a pair of rails 177 that protrude out the
inner sides of the seamless enclosure 154. The two rails 177, which
are similarly shaped, are placed in an opposed relationship
directly across from one another. The rails 177 provide reference
surfaces for receiving and supporting some portion of the internal
components. The portion of the internal components that engages the
rails 177 is typically an edge of the internal components. The
internal rail system 176 is integrally formed with the seamless
enclosure 154. By integral, it is meant that the seamless enclosure
154 and the rail system 176 are formed from a single piece of
material.
In fact, the seamless enclosure 154, which may integrally formed
internal rails 176, is preferably formed from an extrusion process.
The extrusion process produces the desired cross section in a
continuous tube, which can be cut to form a seamless enclosure 154
with or without the internal rails 176 of a desired length. That
is, the seamless enclosure 154, which may include the internal
rails 176 is formed from an elongated continuous extruded tube that
has been cut to a desired length. As should be appreciated, the
features of the internal rail 176 are extruded along with the
seamless enclosure 154 thereby forming rails that have the same
length as the seamless enclosure, i.e., the extrusion process
produces rails that extend from the top to the bottom end of the
seamless enclosure.
The extrusion process allows for a variety of materials. In one
embodiment, the continuous tube is formed from a metal material and
more particularly from aluminum (or some other metal material that
has similar properties to aluminum). In another embodiment, the
continuous tube is formed from a ceramic material and more
particularly from zirconia (or some other ceramic material that has
similar properties to zirconia).
The end caps 156 and 158 can also be made from a variety of
materials such as plastics, ceramics, metals, etc. In one
embodiment, the end caps are formed from a plastic material such as
polycarbonate or ABS using a manufacturing process such as
injection molding.
Moving along, the internal components of the computing device 150
include a printed circuit board 180 that contains various
integrated circuit chips and other circuitry that provide computing
operations for the computing device 150. The printed circuit board
180 may for example include a microprocessor 182, memory 184, a
data port 186, and a switch 188. Although not shown, the printed
circuit board 180 may also contain interconnecting circuitry and
related components that help to operatively couple the various
internal components together. In order to provide access to some of
these components, the top end cap 158 includes an opening 189A for
the switch 188 and the bottom end cap 156 includes an opening 189B
for the data port 186. As shown, the switch 188 may include a
switch cap 191 that is snapped onto the switch 188 after the top
end cap 158 is finally assembled.
The internal components of the computing device 150 also includes a
display 190 such as for example a liquid crystal display. The
liquid crystal display 190 is mounted on the front of the printed
circuit board 180. The LCD 190 may be mounted to the PCB 180 using
a variety of techniques. By way of example, the LCD 190 may include
locking tabs that snap onto the printed circuit board 180 in order
to secure the LCD 190 thereto. Alternatively, the LCD 190 may be a
stand alone assembly, i.e., floating rather than mounted to the PCB
180. In either case, the LCD 190 is operatively coupled to the
printed circuit board 180 and its various components. This may for
example be accomplished through a flex circuit connector that
couples to a connector located on the printed circuit board
180.
In order to provide visible access to the display 190, the seamless
enclosure 154 includes an access opening 192 having a shape that
coincides with the shape of the viewing area of the LCD 190. The
access opening 192 may be formed by processes such as machining,
drilling, cutting, punching and/or the like. In most cases, a clear
window 194 (typically formed from plastic) is positioned in the
access opening 192 in front of the LCD 190 in order to protect the
LCD 190 from damage. In fact, when assembled, the window 194 may be
considered a portion of the housing 152. The window 194 may be
attached to the seamless enclosure 154 using a variety of
techniques including but not limited to fasteners, snaps,
adhesives, etc. In the illustrated embodiment, the window 194
includes a raised section 196 that sits in the opening 192 and that
is either substantially flush or recessed with the outer surface of
the seamless enclosure 154 so that it does not protrude above the
outer surface and a flange section 198 having an adhesive layer
that secures the window 194 to the inner surface of the seamless
enclosure 154. By having the window flush or recessed, scratching
of the window is substantially avoided.
The internal components of the computing device 150 also includes a
hard drive 200. The hard drive 200, which is located at the rear of
the printed circuit board 180, is operatively coupled to the
printed circuit board 180 and its various components. This may for
example be accomplished through a flex circuit connector that
couples to a connector located on the printed circuit board 180.
The hard drive 200 may be mounted (as shown) or it may be free
floating relative to the PCB 180. Although not a requirement, the
hard drive 200 may be surrounded by a plurality bumpers 202 that
serve to protect the hard drive 200 when assembled, i.e., the
bumpers 202 help to prevent shocks to the hard drive 200. They also
may provide a surface that helps retain the hard drive 200 within
the housing 152 (e.g., friction, compliance, etc.). As should be
appreciated, the hard drive gives the device massive storage
capacity unlike flash based devices. By way of example, the hard
drive may have capacities of 5 GB, 10 GB, 15 GB, 20 GB and so on.
To cite an example, when the device is used as a music player, a 20
GB hard drive can store up to 4000 songs or about 266 hours of
music.
The internal components of the computing device 150 also includes a
battery 206. The battery 206, which is located at the rear of the
printed circuit board 180, is operatively coupled to the printed
circuit board 180 and its various components. This may for example
be accomplished through a connector that couples to a connector
located on the printed circuit board 180. In some cases, the
battery may be attached to the backside of the PCB using for
example an adhesive such as double sided tape. In other cases, the
battery 206 may be free floating. By way of example, the battery
may correspond to a rechargeable lithium polymer battery or a
lithium ion prismatic cell. These type of batteries are capable of
offering about 10 hours of continuous playtime to the device
150.
The internal components of the computing device 150 also include an
audio subassembly 210. The audio subassembly 210, which is located
at the top of the printed circuit board 180, is operatively coupled
to the printed circuit board 180 and its various components. The
audio subassembly 210 includes at least a small printed circuit
board 212 and an audio jack 214. The audio subassembly may also
contain various circuit components and interconnecting circuitry,
which are attached to the PCB 212. Although the audio subassembly
may be free floating, in the illustrated embodiment, the audio
subassembly 210 is mechanically coupled to the PCB 180 so that the
PCB 180 and audio subassembly 210 operate as a single unit (i.e.,
form a single structure). By way of example, they may be coupled
together using fasteners, adhesives or snaps.
In one particular embodiment, the audio subassembly 210 is both
operatively and mechanically coupled to the main printed circuit
board 180 and its various components through a connector, which is
located on the audio printed circuit board 212, and which couples
to a connector located on the main printed circuit board 180. The
coupling between the connectors may include a friction element or
mechanical detent that substantially secures the audio subassembly
210 to the printed circuit board 180. In order to provide access to
the audio jack 214 audio subassembly 210, the top end cap 158
includes an opening 193 having a shape that coincides with the
shape of the audio jack 214. Inmost cases, the housing of the audio
jack 214 is substantially flush with the outer surface of the top
end cap 158.
During assembly and referring to the top end of the seamless
enclosure 154, the integrated system comprising, the PCB 180, LCD
190, hard drive 200, battery 206 and audio subassembly 210 is
inserted into the lumen 156 of the seamless enclosure 154 as a
single unit. The printed circuit board 180 essentially acts as a
carrier for placing these components inside the housing 152. During
assembly, the PCB 180 is inserted in the direction of the y axis
into the space provided by a portion of the side and bottom
surfaces of the seamless enclosure 154 as well as the bottom
surface of the internal rail system 176. This space may be referred
to as a channel. During insertion, a top surface of the PCB 180
slides along the bottom surface of the internal rail system 176
within the space. As should be appreciated, the side walls, bottom
surface and rails help constrain the PCB 180 within the housing 152
during and after insertion. The PCB 180 is typically slid into the
seamless enclosure 154 to a depth (y) that places the LCD 190
directly behind the access opening 192. Furthermore, the internal
rail system 176 helps locate the PCB 180 and thus the LCD 190 in
the direction of the z axis while the side walls of the seamless
enclosure 154 help locate the PCB 180 and thus the LCD 190 in the
direction of the x axis.
In order to ensure proper positioning as well as to help secure the
integrated system in place, a top plate 218 may be provided that
prevents further sliding and sets the final position of the
integrated system. The top plate 218 may be attached to the main
PCB 180 or the PCB 212 of the audio subassembly 210. The top plate
218 may be attached using a variety of techniques including but not
limited to fasteners, adhesives, snaps and/or the like. In the
illustrated embodiment, the top plate 218 is attached to the PCB
212 of the audio subassembly 210. When the integrated system is
slid into the lumen 162, the bottom surface of the top plate 218
abuts a recessed area 220 formed in the top surface of the seamless
enclosure 154. The recessed area 220 may for example be formed by
machining a portion of the top surface of the seamless enclosure
154 (including the rails 177). Once positioned against the recessed
area 220, the top plate 218 is attached to the seamless enclosure
154 using fasteners such as screws 219.
The depth of the top plate 218 generally depends on the desired
position of the top end cap 158. In order to produce a flush top
surface, the top plate 218 is typically positioned to a depth
corresponding to the thickness of the top plate 218 and the top end
cap 158. Once the top plate 218 is secured, the top end cap 158 may
be attached thereto. The top end cap 158 may be attached to the top
plate 218 using fasteners, snaps, adhesives, and/or the like. In
order to make assembly easier and to prevent the undesirable look
of fasteners, the top plate 218 may include several retaining
features for receiving tabs located on the inside surface of the
top end cap 158. When the top end cap 158 engages the top plate
218, the tabs are inserted into the retaining features thereby
securing the top end cap 158 to the top plate 218 (via a snapping
action).
In one embodiment, the audio subassembly 210 includes a positioning
adjustment portion (not shown) configured to provide position
relief when attaching the top plate 218 to the seamless enclosure
154. That is, the adjustment portion allows some degree of
tolerance or play so that the top plate 218, which is connected to
the integrated system via the audio subassembly 210, can be
precisely placed relative to the seamless enclosure 154. The
adjustment portion may be separate component or be integrally
formed with the PCB 212. When separate, the adjustment portion may
be or include a compliant member, a flexure, a mechanical mechanism
and/or the like. When integral, the adjustment portion may be a
flexure formed from the PCB 212. In particular, the adjustment
portion may be a tab that has been partially cut away from the PCB
212 thereby enabling it to flex or bend.
The internal components of the computing device 150 also include an
input assembly 230. The input assembly 230 may be widely varied.
The input assembly generally depends on the type of device. In the
illustrated embodiment, the input assembly 230 includes a touch pad
232 and a center switch 234 positioned on a frame 236. The switch
234 is a portion of a button, which may be actuated by a user to
perform actions in the device 150. Although the input device 230 is
structurally separated from the printed circuit board 180, it is
operatively coupled to the printed circuit board 180 and its
various components. This may be accomplished for example through a
flex circuit connector that couples to a connector located on the
printed circuit board 180. This connection is typically made after
the PCB 180 and input device 230 have been inserted into the
seamless enclosure 154.
In some cases, the touch pad 232 is capable of moving relative to
the frame 236 in order to actuate additional mechanical switches
housed within the frame 236. Each of the switches represents a
button, which may be actuated by a user. By way of example, the
input assembly 230 may correspond to any of those input devices
disclosed in U.S. patent application Ser. No. 10/643,256, which is
herein incorporated by reference.
In order to provide user access to the input assembly 230, the
seamless enclosure 154 includes an access opening 237 having a
shape that coincides with the shape of the touch pad 232. Like the
first access opening 192, the second access opening 237 may be
formed from processes (individually or in combination) such as
machining, drilling, cutting, punching and/or the like. In most
cases, a button cap 238 and cover 239 is positioned in the access
opening 237 in front of the touch pad 232 and switch 234 in order
to seal the device 150 and protect the touch pad 232 and switch 234
from damage. The cover 239 is generally sized for placement in the
access opening 237 and to provide a surface that is substantially
flush with the outer surface of the seamless enclosure 154. The
cover 239 is typically attached to the touch pad 232 using an
adhesive. The button cap 238 typically includes a flange potion
that is trapped between the cover 239 and the input assembly 230
thereby securing the button cap 238 to the input assembly 230.
During assembly and referring to the bottom end of the seamless
enclosure 154, the input assembly 230 is inserted into the lumen
156 of the seamless enclosure 154. The frame 236 acts as a carrier
for placing the input assembly 230 inside the housing 152. During
assembly, the input assembly 230 is inserted in the direction of
the y axis into the space provided by a portion of the side and top
surfaces of the seamless enclosure 154 as well as the top surface
of the internal rail system 176. This space may be referred to as a
channel. During insertion, a bottom surface of the frame 236 slides
along the top surface of the internal rail system 176 within the
space. As should be appreciated, the side walls, top surface and
rails help constrain the input assembly 230 within the housing 152
during and after insertion. The input assembly 230 is typically
slid into the seamless enclosure 154 to a depth (y) that places the
touch pad 232 directly behind the access opening 237. The depth may
be set by posts located inside the seamless enclosure. In the
illustrated embodiment, the window 193 includes a pair of abutment
stops 240 that prevents further sliding and sets the final position
of the input assembly 230 in the y direction. Furthermore, the
internal rail system 176 helps locate the touch pad 232 and switch
234 in the direction of the z axis while the side walls of the
seamless enclosure 154 help locate the touch pad 232 and switch 234
in the direction of the x axis.
In order to ensure proper positioning as well as to help secure the
input assembly 230 in place, the input assembly 230 may include a
locking feature that locks the input assembly 230 in place when the
input assembly 230 is finally inserted into the seamless enclosure.
In one embodiment, the locking feature is in the form of a tab 242
that snaps into a recess located on the inner surface of the
seamless enclosure 154. The recess may be formed by machining a
groove in the inner surface of the seamless enclosure 154 at a
position that coincides with the input assembly 230 when it is
finally inserted.
Like the top end, the bottom end may include a structural plate,
i.e., bottom plate 244. The bottom plate 244 is configured to act
as a reference support surface for the bottom end cap 156. It may
also act as a reference surface for the input assembly 230 or the
main system assembly. The bottom plate 244 may be connected to the
seamless enclosure 154 and/or the input assembly 230. The bottom
plate 244 may be attached using a variety of techniques including
but not limited to fasteners, adhesives, snaps and/or the like. By
way of example, the bottom plate 244 may be connected in a manner
similar to the top plate (attached to the input assembly and
inserted into a recess).
Alternatively, as shown in the Figure, the bottom plate 244 may
include retaining features 246 that snap into recesses formed in
the inner surface of the seamless enclosure 154 thereby
mechanically securing the bottom plate 244 to the seamless
enclosure 154. The recesses may be formed by machining grooves in
the inner surface of the seamless enclosure 154 at a position that
coincides with the retaining features 246 when the bottom plate 244
is inserted in the seamless enclosure 154. During assembly, the
retaining features 246 are flexed inwardly, and the bottom plate
244 is placed inside the seamless enclosure 154. Once the bottom
plate 244 is correctly positioned next to the recesses, the
retaining features 246 are unflexed outwardly thereby causing them
to be outwardly extended into the recesses, i.e., the retaining
features 246 are received by the recesses. A tool may be required
to flex the retaining features in a manner analogous to retaining
rings. Unlike retaining rings, however, the bottom plate is not
circular, and spans the inside of the enclosure to support internal
and external parts. Furthermore, the bottom plate is fixed in place
and cannot rotate as circular retaining rings thus providing a
reference surface in more than just the y direction, i.e., the
bottom plate provides a reference surface in the x, y and z
directions. This enables the bottom plate to fixedly support the
end cap.
The depth of the bottom plate 244 generally depends on the desired
position of the bottom end cap 156. In order to produce a flush
bottom surface, the bottom plate 244 is typically positioned to a
depth corresponding to the thickness of the bottom plate 244 and
the bottom end cap 156. Once the bottom plate 244 is secured, the
bottom end cap 156 may be attached thereto. The bottom end cap 156
may be attached to the bottom plate using fasteners, snaps,
adhesives, and/or the like. In order to make assembly easier and to
prevent the undesirable look of fasteners, the bottom plate 244 may
include several retaining features for receiving tabs located on
the inside surface of the bottom end cap 156. When the bottom end
cap 156 engages the bottom plate 244, the tabs are inserted into
the retaining features thereby securing the bottom end cap 156 to
the bottom plate (via a snapping action).
The bottom plate may be formed from a variety of materials such as
metals and plastics. The material that is selected typically offers
a balance between resistance to deformation so as to provide a
structural surface and bendability so that the flexure arms can be
flexed during installation. In the illustrated embodiment, the
bottom plate is formed from stainless steel, and more particularly
high hardness stainless steel.
Although not shown, the internal components may also include
components for processing, transmitting and/or receiving wireless
signals (e.g., transmitter, receiver, antenna, etc.). By way of
example, the device may include components for supporting FM, RF,
Bluetooth, 802.11, etc.
In one embodiment, the device is or includes functionality for
supporting cellular or mobile phone usage. In this embodiment, the
device includes processors, transmitters, receivers, and antennas
for supporting RF, and more particularly GSM, DCS and/or PCS
wireless communications in the range of about 850 to about 1900
MHz.
The device may for example include one or more antennas tuned to
operate over the GSM, PCS and/or DCS frequency bands. By way of
example, monopole, dipole and tri band and quad band antennas may
be used. In one example, a PCS+DCS dipole antenna is used. The
antenna may protrude out of the enclosure or it may be fully
enclosed by the enclosure. If the later, some portion of the
enclosure is configured to be radio transparent (e.g., capable of
transmitting and receiving RF signals therethrough). For example,
the end caps and/or the main body of the enclosure may be
radio-transparent.
In one implementation, the main body is formed from a ceramic
material that is radio-transparent. By utilizing a ceramic
enclosure that is radio-transparent, an internal antenna may be
used, which is typically more robust and durable than an external
antenna. Furthermore, many advantages regarding the use of an
internal antenna may be achieved. For example, a smaller and
cheaper antenna may be used. Furthermore, the antenna can be
integrated with other components and placed at almost any location
within the enclosure, which helps make a smaller and more compact
device in addition to reducing the cost of manufacture.
An example of wireless communication devices and mechanisms can be
found in U.S. patent application Ser. No. 10/423,490, which is
herein incorporated by reference.
FIG. 4, which is top view, in cross section of the assembled device
150, shows the position of the various components of the integrated
system inside the housing 152 and more particularly the seamless
enclosure 154. As shown, the top surface at the edge of the printed
circuit board 180 abuts the bottom surface of the rails 177.
Furthermore, the battery 206 and hard drive 202 are contained
within the lower channel formed by the rails, sides and back
surface of the seamless enclosure 154. In most cases, there is a
snug fit between these components and the surrounding portions of
the seamless enclosure 154 so as to help hold the integrated system
in place. Moreover, the LCD 190 protrudes above the rails 177
through a gap formed between the rails 177 so that it is positioned
directly underneath the window 194. In some cases, the gap may be
dimensioned to form a snug fit between the LCD and rails to better
align the LCD with the opening, i.e., the rails provide a reference
surface for the LCD in the x direction.
FIG. 5, which is bottom view, in cross section of the assembled
device 150, shows the position of the input assembly 230 inside the
housing 152, and more particularly the seamless enclosure 154. As
shown, the bottom surface at the edge of the frame 236 abuts the
top surface of the rails 177. Furthermore, most of the input
assembly 230 is contained within the upper channel formed by the
rails, sides and surface of the seamless enclosure 154. In most
cases, the input assembly 230 is sized and dimensioned to fit
snuggly inside the upper channel. A small portion of the frame (or
other component of the input assembly 230) may be positioned within
the gap formed between the two rails 177.
FIGS. 6A-6C show the insertion and mounting of the input assembly
230 inside the seamless enclosure 154. As shown in FIGS. 6A and 6B,
the input assembly 230 is inserted into the bottom end of the
seamless enclosure 154. In particular, the front edge of the input
assembly 230 is placed within the upper channel against the rails
177, and the input assembly 230 is slid along the rails 177 into
the seamless enclosure 154. As shown in FIG. 6C, when the input
assembly 230 nears its final position in the y direction, the tab
242 on the rear of the input assembly 230 snaps into a recess 256
located on the inner top surface of the seamless enclosure 154
thereby securing the input assembly 230 between this point and the
abutment stops 240 located on the window 194. The positions of the
abutment stop 240 and recess 256 are preferably positioned such
that the tab 242 engages the recess 256 as the input assembly 230
presses against the abutment stop 240. This particular arrangement
helps prevent any subsequent movement of the input assembly 230,
i.e., locks it into place (in the y direction).
FIGS. 7A and 7B show the bottom plate 244 in its unassembled and
assembled positions. The bottom plate 244 includes a body 261 and a
plurality of flexure arms 246. The body 261 is typically configured
to fill the available space between the opposing sets of retaining
arms 256 so as to produce a more rigid structure for supporting the
various components enclosed within or attached to the enclosure
154. The flexure arms 246, which extend from the body 261, are
configured to bend in towards the body 261 when a force F is
applied to the flexure arms 246. In some cases, the interface
between the body and the flexure arms includes a radius. The radius
may be adjusted to tune the stiffness of the flexure arms. The
force F may for example be provided by a pinching tool that engages
holes 262 located in each of the flexure arms 246.
Both the body and the arms are configured to cooperate to form the
shape of the bottom plate. The shape may be widely varied although
the shape is generally configured to be non circular so as to
provide a better reference surface (e.g., substantially
rectangular). In fact, the shape may coincide with the shape of the
lumen found in the enclosure.
The bottom plate 244 may be formed from a variety of structural
materials including metals and plastics. By way of example, the
bottom plate 244 may be formed from stamping a sheet of metal
(e.g., steel) or from molding a piece of plastic.
As shown in FIG. 7B, the bottom plate 244 is positioned inside the
lumen 162 of the seamless enclosure 154. In particular, the flexure
arms 246 are retained within slots 263 located on the inside
surface of the seamless enclosure 154. In fact, the flexure arms
may include outward protrusions that provide a better interface
between the flexure arms and the slots. The bottom plate 244, which
is designed to receive the bottom end cap 156, is positioned at the
end of the seamless enclosure 154 so as to produce a reference
support surface for the bottom end cap 156. In essence, the bottom
plate 244 when retained acts as an extension of the seamless
enclosure 154. The depth of the bottom plate 244 is typically
configured to place the outer surface of the bottom end cap 244
substantially flush with the bottom surface 264 of the seamless
enclosure 154. The bottom plate 244 may include various features
266 for receiving locking tabs located on the bottom end cap 156.
As should be appreciated, the features may be openings or voids
that receive snaps on the bottom of the end cap, i.e., the snaps
snap into the openings thereby securing the bottom end cap to the
bottom plate. The bottom plate 244 may also include an opening 267,
which provides a clearance for the connector 186.
FIG. 8 is a diagram of the audio subassembly 210, in accordance
with one embodiment of the present invention. As shown in FIG. 8A,
the PCB 212 is divided into a flexure portion 270, a first base
portion 272 and a second base portion 274. This may be accomplished
by cutting a groove in the PCB 212. The audio jack 214 is attached
to the first base portion 272 and the top plate 218 is attached to
the audio jack 214. The second base portion 274 includes a
connector 276 that mates with a connector on the main PCB 180 in
order to operatively and mechanically couple the audio subassembly
210 to the main PCB 180, i.e., form a single unit. The flexure
portion 270 is positioned between the first and second base
portions 272 and 274. The flexure portion 270 allows the first base
portion 272 to move relative to the second base portion 274. The
flexure 270 causes the first base portion 272 and thus the top
plate 218 to float relative to the main PCB 180 while still being
constrained thereto. As shown in FIGS. 8B and 8C, the flexure
portion 270 is capable of flexing or bending so that the first base
portion 272 can shift relative to the second base portion 274
thereby allowing the top plate 218 to be correctly aligned with the
recess 220 of the seamless enclosure 154. That is, the flexure 270
allows the top plate 218 to shift into mating engagement with the
recess 220 of the seamless enclosure 154 thereby producing a tight
fit between the top plate 218 and the seamless enclosure 154.
FIG. 9A-9H are various diagrams of the seamless enclosure 154. As
shown, the seamless enclosure 154 includes a planar front surface
280, a back planar surface 282 and rounded sides 284. The access
openings 192 and 237 for the LCD 190 and input assembly 230 are
located in the front planar surface 280. The seamless enclosure 154
also includes a lumen 162 therethrough that defines openings at
each of the ends of the seamless enclosure 154. The rails 177,
which extend substantially through the lumen 162, are located in an
opposed relationship inside the lumen 162. The rails 177 protrude
away from the sides of the lumen 162 and are positioned closer to
the front planar surface 280 than the back planar surface 282. The
end at the top of the seamless enclosure 154 includes a recess 220
for receiving the top plate 218 and top end cap 158. The recess 220
essentially forms a lip to which the top plate 218 is secured. The
end at the bottom of the seamless enclosure 154 includes a cut out
section 290 for receiving the bottom plate 244 and the bottom end
cap 156. The cut out 290 is formed by shortening the ends of the
rails 177. This end also includes a plurality of slots 263 for
receiving the flexure arms 246 of the bottom plate 244.
It should be noted that the invention is not limited this
particular form factor. For example, the cross sectional shape,
width, thickness, height of the enclosure can all be adjusted
according to the needs of the device. For example, in some cases,
the width and thickness may be reduced while increasing the height.
In addition, the openings in the enclosure can also be modified and
may take on other shapes. For example, the LCD window may be
increased in height, and the touch pad circle may be decreased in
diameter. In one example, the enclosure may have dimensions similar
to the iPod Nano manufactured by Apple Computer of Cupertino,
Calif.
It should also be noted that completely different form factors may
be used. For example, the device may correspond to smaller more
compact devices such as the Shuffle and remote controls
manufactured by Apple Computer of Cupertino, Calif.
FIG. 10 is a method of manufacturing an electronic device 340, in
accordance with one embodiment of the present invention. The
electronic device may generally correspond to any of those
previously described. The method generally includes several
operations including: the formation of the housing 342, the
assembly of the internal components including the main system
assembly 244 and the touch pad assembly 346, and the final assembly
of the housing 348.
Referring first to the formation of the housing 342, the operation
starts with block 352 where a tube having internal rails is
extruded. Alternatively, the tube can be extruded without internal
rails or with other internal features. Following block 352, the
operation proceeds to block 354 where the extruded tube is cut to a
desired length. Following block 354, the operation proceeds to
block 356 where the access openings are formed in the extruded
tube. By way of example, the access opening may be associated with
a user interface of the electronic device. Following block 356, the
operation proceeds to block 358 where a recess is formed into a top
surface of the extruded tube. Following block 358, the operation
proceeds to block 360 where one or more threads are formed in the
recess at the top surface of the extruded tube. Following block
360, the operation proceeds to block 362 where a portion of the
internal rails are removed from the bottom surface of the extruded
tube if the internal rail system is used. Following block 362, the
operation proceeds to block 364 where slots are formed in the
bottom surface of the extruded tube as for example in the location
where the internal rails were removed.
Referring to the assembly of the various components inside the tube
344, the operation starts with block 366 where a window is mounted
in one of the access openings. This may for example be accomplished
using an adhesive such as glue or tape. Following block 366, the
operation proceeds to block 368 where a main system assembly is
inserted into the top end of the extruded tube along the lower
surface of the internal rails. The main system assembly is
typically sized and dimensioned for sliding receipt between the
lower surface of the internal rails and the side and back surface
of the extruded tube. The main system assembly generally includes a
printed circuit board, which acts as the carrier for several
components including: system electronics (e.g., microprocessor and
memory); an LCD; a battery; I/O assemblies (audio assembly, data
port assembly); etc. Following block 368, the operation proceeds to
block 370 where the main system assembly is mounted to the extruded
tube. This is generally accomplished through a top plate that is
attached to the main system assembly. When the main system assembly
is finally inserted into the extruded tube, the top plate presses
against the upper surface of the recess thereby setting the
position of the main system assembly in its desired position along
the longitudinal axis of the extruded tube. The top plate is then
attached to the extruded tube via screws and the previously formed
threads.
Referring to the assembly of the touch pad assembly 346, the
operation starts with block 372 where the touch pad assembly is
inserted into the bottom end of the extruded tube along the upper
surface of the internal rails. The touch pad assembly is typically
sized and dimensioned for sliding receipt between the upper surface
of the rail and the side and front wall of the extruded tube. When
the touch pad assembly is finally inserted into the extruded tube,
the top surface of the touch pad assembly presses against a pair of
abutment stops located at the bottom end of the window thereby
setting the position of the touch pad assembly in its desired
position along the longitudinal axis of the extruded tube. In
particular, the touch pad of the touch pad assembly is positioned
directly behind the second access opening.
Following block 372, the method proceeds to block 374 where the
touch pad assembly is operatively coupled to the main system
assembly. By way of example, a simple connector connection may be
made or a solder connection can be made. In the illustrated
embodiment, the touch pad assembly includes a flex connector that
couples to a connector located on the PCB. Following block 374, the
operation proceeds to block 376 where a button cap and label is
situated over the touch pad of the touch pad assembly. The button
cap is disposed over a center switch and the label is disposed over
an edge of the button cap as well as the touch pad. The label is
typically attached to the touch pad using an adhesive. In most
cases, the label is positioned in the recessed area formed by the
touch pad and the edge of the access opening. The label therefore
helps to secure the touch pad assembly in its desired position
within the extruded tube. Although not a requirement, the top
surface of the label is typically positioned substantially flush
with the outer surface of the extrude tube.
Referring to the final assembly of the device, the operation starts
with block 378 where the snap plate is inserted into the slotted
bottom end of the extruded tube thereby securing the snap plate to
the extruded tube. Following block 378, the operation proceeds to
block 380 where the bottom end cap is mounted to the bottom end of
the extruded tube. This is generally accomplished by positioning
the bottom end cap in the recessed area formed by the snap plate
and the inner surface of the extruded tube, and snapping tabs
located on the bottom end cap into the snap plate thereby securing
the bottom end cap to the snap plate. In most cases, the outer
surface of the bottom end cap is made flush with the bottom surface
of the extruded tube. Following block 380, the operation proceeds
to block 382 where the top end cap is mounted to the top end of the
extruded tube. This is generally accomplished by positioning the
top end cap in the recessed area formed by the top plate and the
inner surface of the extruded tube, and snapping tabs located on
the top end cap into the top plate thereby securing the top end cap
to the top plate. It should be pointed out that during insertion of
the top end cap into the recessed area, a protruding member of the
audio assembly is inserted through an opening in the top end cap.
Because the audio assembly includes a flexure, the protruding
member has a small amount of tolerance or play that allows for easy
placement through the opening. Once the top end cap is attached,
the switch cap may be placed on the switch assembly through another
opening in the top end cap.
FIG. 11 is a method 400 of creating a ceramic enclosure, in
accordance with one embodiment of the present invention. The
ceramic enclosure may be embodied in various forms including any of
those previously mentioned.
The method 400 begins at block 402 where a ceramic material is
provided. The ceramic material may be in a form ready for forming
or it may be in a raw state. If in a raw state, raw material
processing is typically performed to ready it for forming. For
example, a co-precipitation method may be performed in order to
produce Y203 stabilized zirconia. Zirconia may be embodied in a
variety of colors including white, black, navy blue, ivory, brown,
dark blue, light blue, platinum, gold (among others). The colors
may for example be created by adding doping materials to the
ceramic material. Other materials may also be added including
Yttrium, which helps keep the crystalline structure intact across
all temperatures especially for maintaining strength as the part
cools down.
The base material of zirconia is zirconium oxide. Zirconia may also
include a variety of other components as for example yttrium oxide,
chromium oxide, aluminum oxide, hafnium oxide, and/or the like. In
one example, the composition of black zirconia comprises greater
than or equal to 89% ZrO.sub.2 (zirconium oxide), less than or
equal to 7% Y.sub.2O.sub.3 (yttrium oxide), less than or equal to
3% Cr.sub.2O.sub.3 (chromium oxide), and less than or equal to 3%
Al.sub.2O.sub.3 (aluminum oxide). In another example, the
composition of white zirconia comprises greater than or equal to
93% ZrO.sub.2 (zirconium oxide), less than or equal to 7%
Y.sub.2O.sub.3 (yttrium oxide), and less than or equal to 1%
Al.sub.2O.sub.3 (aluminum oxide). In each of these examples, the
composition may also include 1-2% Hf0.sub.2 (hafnium oxide). It
should be appreciated that these examples are given by way of
example and not by way of limitation.
Following block 402, the method 400 proceeds to 404 where a forming
process is performed in order to produce a ceramic enclosure in a
green state. In one embodiment, an extrusion process is performed.
Extrusion is a process where ceramic material is pushed or drawn
through a die to create the shaped enclosure formed from green
ceramic. The design of the extrusion die is important in ensuring
that homogenous densities are produced in the different wall
sections of the enclosure. The process typically generates a long
length of product. Once extruded, the green ceramic extrusion is
typically separated from a continuous length into one or more
enclosures. By way of example, the continuous length of green
ceramic material may be cut to a desired length. Alternatively, the
enclosures may be formed by dry pressing and machining. However, it
is generally believed that extrusion offers the benefits of tuned
density (more uniform) in green state, yielding improved part
strength and dimensional characteristics.
Thereafter, in block 406, the green state ceramic enclosures are
sintered. Sintering is the process of heating a compressed green
material to form a solid cohesive body. It is sometimes referred to
as firing. Sintering may for example be performed in kilns such as
batch kilns or continuous kilns. Batch kilns are good for
controlling and debugging parameters. Continuous kilns are good for
cranking out parts in volume. Temperatures for sintering may for
example be around 1400 degrees C. In one example, for sintering
zirconia enclosures, the enclosures are fired at 500 degrees C. for
5 hours, then raised to 1400 degrees C. for roughly 4 hours, then
cooled back down to room temperature. Sintering may shrink the
enclosure up to 50% of the green state size and therefore this
reduction should be taken into account when designing the extrusion
die.
Following block 406, the method 400 proceeds to 408, where one or
more grinding operations are performed. Grinding is the process of
removing material via abrasion as for example from materials to
hard to be machined. Grinding may be performed to achieve two
effects (1) to shape the enclosure and/or (2) to obtain a high
degree of dimensional accuracy and surface finish. The grinding
process may include a rough grind that will remove a majority of
material and create a flat part and then a fine grind to create the
final shape. The grinding operations may also be used to cut holes
and features into the enclosure as for example cut the openings in
the front face of the enclosure. A CNC machine may be used to
perform some or all of the grinding operations. Alternatively, the
openings and features may be made with laser cutting, jet cutting
or ultrasonic cutting means. In some cases, lapping operations are
performed to achieve extreme dimensional accuracy and superior
surface finishes. In one implementation, the top and bottom
surfaces are first lapped to a tight tolerance and then the edges
are lapped thereafter.
In some cases, the parts may be machined in the green state in
addition to or instead of grinding after solidification.
In one embodiment, the wall thickness of the enclosure after the
grinding steps is between 0.8 mm and about 1.2 mm.
Thereafter, in block 410, the enclosures are tumbled to remove
burrs from edges of the enclosure as well as to remove
micro-cracking from the grinding process. For example, multiple
parts are thrown in a tumbler bin, which is rotated for several
hours (e.g., 10 hours).
Thereafter in block 412, a surface finishing operation may be
performed. In one embodiment, a second tumbling operation is
performed to create a smooth (gloss) finish. In another embodiment,
a blasting operation is performed to create a rough (matte) finish.
By way of example, the blasting operation may use silicone carbide
as a medium.
Following block 412, the method 400 proceeds to blocks 414 and 416
where the enclosures are cleaned and inspected. The inspection may
include micro photography as well as chemical composition analysis.
When approved, the enclosures can be used to assemble the final
product (e.g., internal components inserted inside).
In some cases, the method 400 may include an additional step of
applying a protective coating or protective features to the outside
of the ceramic enclosure. This may be performed before or after
placement of the internal components. The coatings or features may
for example be formed from deformable materials such as silicon,
foam or rubber materials. The coatings or protective features are
typically positioned on the exterior surface to prevent cracking
and protect the ceramic shell from undesirable forces as for
example when the ceramic shell is dropped. The coatings and
protective features can be placed almost anywhere on the ceramic
shell, but in most cases are placed at least at the edges where the
ceramic shell may be susceptible to cracking. In some cases, the
end plates may even serve this function.
Although the invention has been primarily directed at a single
enclosure (except for the end plates), it should be appreciated
that in some cases the enclosure may be formed from multiple parts
rather than a single integrally formed piece. Each of these parts
may be extruded or otherwise formed. Furthermore, they may be
formed from the same materials (zirconia/zirconia), same class of
materials (first ceramic material/second ceramic material) or from
different classes of materials (ceramic/metal, ceramic/plastic,
plastic/metal or ceramic/plastic/metal). By way of example, it may
be beneficial to combine materials to obtain each of the materials
advantages. Any combination may be used. Moreover, the multiple
parts may include frame components with plates attached thereto, or
a top member and a bottom member that are attached together. The
attachment means may be widely varied and may include such things
as fasteners, glues, epoxies, double sided tape, snaps, mechanical
interlocks that are molded together, and the like. One example of
connecting parts together can be found in U.S. Pat. No. 7,012,189
and U.S. application Ser. No. 10/928,780, both of which are herein
incorporated by reference.
FIG. 12 shows one embodiment of an enclosure 500 that includes a
frame 502 with plates 504 attached thereto. The plates 504 may be
embodied as front plates, back plates, side plates, end plates
and/or the like. The frame 502 forms at least the edges of the
enclosure (as shown) and in some cases may also include side walls,
front wall, back wall or end caps (e.g., forms at least a skeletal
system with cross bracing). The frame 502 forms at least one
opening 506 for placement of a plate 504. The opening 506 may
include a recessed portion on which the plate 504 can be seated.
Furthermore, the plate 504 can be attached using any suitable
attachment means as for example an epoxy. In the illustrated
embodiment, the frame 502 includes openings 506A and 506B for front
plates 504A and back plates 504B. Furthermore, this design can be
made with or without using end caps.
The materials of the frame and plates may be widely varied. In one
embodiment, the enclosure includes a metal or plastic frame with
ceramic plates attached thereto. For example, the frame may be
formed from aluminum or ABS plastic, and the plates may be formed
from zirconia. In another embodiment, the enclosure includes a
plastic frame with metal plates. In another embodiment, the
enclosure includes a metal frame with plastic plates. In yet
another embodiment, the enclosure includes a metal or plastic frame
with plates formed from metal, plastic or ceramic.
FIG. 13 shows one embodiment of an enclosure 550 that includes a
top member 552 with a bottom member 554 attached thereto. The top
and bottom member 552 and 554 can be formed from the same or
different materials as mentioned above. In one embodiment, the top
member 552 is formed from metal such as aluminum, the bottom member
554 is formed from ceramic such as zirconia (or vice versa). In
another embodiment, the top member 552 is formed from plastic such
as polycarbonate, and the bottom member 554 is formed from ceramic
such as zirconia (or vice versa) or a metal such as aluminum (or
vice versa). In yet another embodiment, the top member 552 is
formed from ceramic such as zirconia or alumina, and the bottom
member 554 is formed from ceramic such as zirconia or alumina. As
should be appreciated, any combination can be used. Furthermore,
this design can be made with or without using end caps. For
example, the top and bottom members may include a closed end.
Moreover, although not shown, the various components of the
enclosure may consist of multiple layers that are glued, press fit,
molded or otherwise secured together. In one example, the enclosure
consists of multiple layers that form a single laminate structure
formed for example by gluing. By way of example, the entire or
portions of the enclosure walls may be formed from layers of
metals, ceramics and/or plastics. In the case of radio
transparency, the layers may include plastics and ceramics as for
example forming a wall with a plastic outer layer and a ceramic
inner layer (or vice versa).
Generally speaking, when using an internal antenna, it is desirable
to increase the radio transparency of the enclosure in order to
effectively perform wireless transmissions therethrough. Thus, a
substantial portion of the enclosure is formed form materials
capable of providing radio-transparency (e.g., ceramics, plastics,
etc.). In most cases, the radio transparent portions of the
enclosure constitutes a significant area of the entire enclosure.
For example, greater than 50%, more particularly greater than 75%,
and even more particularly greater than 85%. The radio transparent
portions may even be greater than 90%, and more particularly
greater than 95%, and in some cases 100% of the enclosure.
The radio transparent portions may be embodied in a variety of
ways. In one embodiment, the radio transparent portions constitute
the entire enclosure. For example, all the walls of the enclosure
are radio transparent (e.g., both the main body and the end caps).
In another embodiment, the radio transparent portions constitute
one or more walls of the housing. For example, the top and/or
bottom member of the enclosure shown in FIG. 13 or one or more
plates of the enclosure shown in FIG. 12. In another embodiment,
the radio transparent portions may constitute a part of one or more
walls of the enclosure. That is, only a portion of a wall may be
radio transparent. For example, the wall may be separated into two
parts, or in the case of a laminated wall, some portion of the wall
may include a non radio transparent layer.
It is generally believed that a greater area of radio transparency
produces a stronger signal during transmissions and stronger
reception when a signal is received. However, other factors may
play a role as for example the location of the internal antenna. By
way of example, in an enclosure with a decreased amount of radio
transparency, the internal antenna may be positioned closer or
proximate to the radio transparent portions of the enclosure.
Furthermore, it should be noted that although non radio transparent
portions such as metals typically degrade radio transmissions, in
some cases, non radio transparent portions may be designed in such
a manner as to enhance or help radio transmissions.
While this invention has been described in terms of several
preferred embodiments, there are alterations, permutations, and
equivalents, which fall within the scope of this invention. For
example, although the invention includes at an integrally formed
internal rail system, in some cases the internal rail system may be
a separate component that is attached within the main body or it
may not even be included in some cases. It should also be noted
that there are many alternative ways of implementing the methods
and apparatuses of the present invention. For example, although an
extrusion process is preferred method of manufacturing the integral
tube, it should be noted that this is not a limitation and that
other manufacturing methods may be used in some cases (e.g.,
injection molding, press forming). In addition, although the
invention is directed primarily at portable electronic devices such
as media players, and cell phones, it should be appreciated that
the technologies disclosed herein can also be applied to other
electronic devices such as remote controls, mice, keyboards,
monitors, and accessories for such devices. It is therefore
intended that the following appended claims be interpreted as
including all such alterations, permutations, and equivalents as
fall within the true spirit and scope of the present invention.
* * * * *
References